Danfoss VLT AutomationDrive FC 301 Instruction Manual Download Page 3

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Contents

1 Introduction

1.1 Purpose of the Manual

1.2 Additional Resources

1.3 Document and Software Version

1.4 Product Overview

1.5 Approvals and Certifications

1.6 Disposal

2 Safety

2.1 Safety Symbols

2.2 Qualified Personnel

2.3 Safety Precautions

3 Mechanical Installation

3.1 Unpacking

3.1.1 Items Supplied

3.2 Installation Environments

3.3 Mounting

4 Electrical Installation

4.1 Safety Instructions

4.2 EMC-compliant Installation

4.7 AC Line Input Connection

4.8 Control Wiring

4.8.1 Control Terminal Types

4.8.2 Wiring to Control Terminals

4.8.3 Enabling Motor Operation (Terminal 27)

4.8.4 Voltage/Current Input Selection (Switches)

4.8.5 Mechanical Brake Control

4.8.6 RS-485 Serial Communication

4.9 Installation Check List

5 Commissioning

5.1 Safety Instructions

5.2 Applying Power

Contents

Instruction Manual

MG33AP22

Summary of Contents for VLT AutomationDrive FC 301

Page 1: ...MAKING MODERN LIVING POSSIBLE Instruction Manual VLT AutomationDrive FC 301 302 0 25 75 kW www danfoss com drives...

Page 2: ......

Page 3: ...on 13 4 1 Safety Instructions 13 4 2 EMC compliant Installation 13 4 3 Grounding 13 4 4 Wiring Schematic 14 4 5 Access 16 4 6 Motor Connection 16 4 7 AC Line Input Connection 17 4 8 Control Wiring 17...

Page 4: ...on 31 5 7 Local Control Test 31 5 8 System Start up 31 6 Application Set up Examples 32 7 Maintenance Diagnostics and Troubleshooting 38 7 1 Maintenance and Service 38 7 2 Status Messages 38 7 3 Warni...

Page 5: ...n Tightening Torques 76 8 9 Power Ratings Weight and Dimensions 77 9 Appendix 79 9 1 Symbols Abbreviations and Conventions 79 9 2 Parameter Menu Structure 79 Index 85 Contents Instruction Manual MG33A...

Page 6: ...dated All suggestions for improvement are welcome Table 1 1 shows the document version and the corresponding software version Edition Remarks Software version MG33APxx Replaces MG33AOxx 7 XX Table 1 1...

Page 7: ...slot 4 Digital I O and 24 V power supply 14 Grounding clamp PE 5 Analog I O connector 15 Cable shield connector 6 Cable shield connector 16 Brake terminal 81 82 7 USB connector 17 Load sharing termina...

Page 8: ...2 and load sharing 88 89 terminals 5 Analog switches A53 A54 14 Line power input terminals 91 L1 92 L2 93 L3 6 Cable shield connector 15 USB connector 7 Decoupling plate 16 Serial bus terminal switch...

Page 9: ...tor Area Title Functions 8 Control circuitry Input power internal processing output and motor current are monitored to provide efficient operation and control User interface and external commands are...

Page 10: ...on manual 2 3 Safety Precautions WARNING HIGH VOLTAGE Adjustable frequency drives contain high voltage when connected to AC line power input DC power supply or load sharing Failure to perform installa...

Page 11: ...off Table 2 1 Discharge Time WARNING LEAKAGE CURRENT HAZARD Leakage currents exceed 3 5 mA Failure to ground the adjustable frequency drive properly can result in death or serious injury Ensure the co...

Page 12: ...and current at low high voltages 6 Output voltage frequency and current at low high voltages 7 Enclosure type and IP rating 8 Maximum ambient temperature 9 Certifications 10 Discharge time Warning Fi...

Page 13: ...it For lifting use hoist rings on the unit when provided Mounting 1 Ensure that the strength of the mounting location supports the unit weight The adjustable frequency drive allows side by side instal...

Page 15: ...ons regarding cross section and ambient temperature requirements Power connection wire recommendation minimum 167 F 75 C rated copper wire See chapter 8 1 Electrical Data and chapter 8 5 Cable Specifi...

Page 16: ...801 0 4 20 mA RS 485 RS 485 03 10 V DC 0 10 V DC 10 V DC 10 V DC 0 4 20 mA 0 10 V DC 240 V AC 2 A 24 V DC 02 01 05 04 06 24 V NPN 0 V PNP 0 V PNP 24 V NPN 19 D IN 24 V NPN 0 V PNP 27 24 V 0 V D IN OUT...

Page 17: ...Min 7 9 in 200 mm 6 Cable connector Figure 4 2 EMC compliant Electrical Connection For more information about EMC see chapter 4 2 EMC compliant Installation NOTICE EMC INTERFERENCE Run cables for inpu...

Page 18: ...with local and national electrical codes for cable sizes For maximum wire sizes see chapter 8 1 Electrical Data Follow the motor manufacturer wiring requirements Motor wiring knockouts or access pane...

Page 19: ...figuration of the equipment connect the input power to the line power input terminals or the input disconnect 3 Ground the cable in accordance with the grounding instructions provided in chapter 4 3 G...

Page 20: ...ailable for use with the MCT 10 Set up Software Terminal description Terminal Parameter Default setting Description Digital inputs outputs 12 13 24 V DC 24 V DC supply voltage for digital inputs and e...

Page 21: ...g Control Wires 2 Insert the bare control wire into the contact 3 Remove the screwdriver to fasten the control wire into the contact 4 Ensure that the contact is firmly established and not loose Loose...

Page 22: ...l output terminal 27 or 29 Keep the output closed voltage free as long as the adjustable frequency drive is unable to keep the motor at standstill for example due to the load being too heavy Select 32...

Page 23: ...internal to the adjustable frequency drive Danfoss FC Modbus RTU Functions can be programmed remotely using the protocol software and RS 485 connection or in parameter group 8 Communications and Opti...

Page 24: ...is adequate to ensure proper air flow for cooling see chapter 3 3 Mounting Ambient conditions Check that requirements for ambient conditions are met Fusing and circuit breakers Check for proper fusin...

Page 25: ...1 Confirm that the input voltage is balanced within 3 If not correct the input voltage imbalance before proceeding Repeat this procedure after the voltage correction 2 Ensure that any optional equipm...

Page 26: ...5 1 Display Area B Display menu keys Menu keys are used for menu access for parameter set up toggling through status display modes during normal operation and viewing fault log data Key Function 6 St...

Page 27: ...en requires setting functions in several related parameters Details for parameters are provided in chapter 9 2 Parameter Menu Structure Programming data is stored internally in the adjustable frequenc...

Page 28: ...ion and press OK 4 Remove power to the unit and wait for the display to turn off 5 Apply power to the unit Default parameter settings are restored during start up This may take slightly longer than no...

Page 29: ...in place between control terminals 12 and 27 leave 5 12 Terminal 27 Digital Input at factory default Otherwise select No Operation in 5 12 Terminal 27 Digital Input For adjustable frequency drives wi...

Page 30: ...commendations for Flux Applications 5 4 4 PM Motor Set up This section describes how to set up a PM motor Initial programming steps To activate PM motor operation select 1 PM non salient SPM in 1 10 M...

Page 31: ...ing torque 100 current provides nominal torque as starting torque This parameter is independent from 30 20 High Starting Torque Time s and 30 21 High Starting Torque Current Working at current level h...

Page 32: ...t Applications If the motor starts oscillating at a certain speed increase 1 14 Damping Gain Increase the damping gain value in small steps Depending on the motor an optimum value for this can be 10 o...

Page 33: ...PM that the feedback is positive NOTICE If the feedback is negative the encoder connection is wrong 5 7 Local Control Test 1 Press Hand On to provide a local start command to the adjustable frequency...

Page 34: ...D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 130BB929 10 Function Setting 1 29 Automatic Motor Adaptation AMA 1 Enable complete AMA 5 12 Terminal 2...

Page 35: ...37 is an option Table 6 4 Analog Speed Reference Current Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 A5...

Page 36: ...ion Table 6 7 Start Stop Command with Safe Stop Option 130BB805 11 Speed Start 18 Figure 6 2 Start Stop Command with Safe Stop Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN...

Page 37: ...ameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 130BB928 10 Function Setting 5 11 Terminal 19 Digital Input 1 R...

Page 38: ...mistor 6 1 7 SLC Parameters FC 24 V 24 V D IN D IN D IN COM D IN D IN D IN D IN 10 V A IN A IN COM A OUT COM R1 R2 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 01 02 03 04 05 06 130BB839 10 Functio...

Page 39: ...IN A IN COM A OUT COM R1 R2 12 13 18 19 20 27 29 32 33 37 50 53 54 55 42 39 01 02 03 04 05 06 130BB841 10 Function Setting 5 40 Function Relay 32 Mech brake ctrl 5 10 Terminal 18 Digital Input 8 Star...

Page 40: ...ble frequency drive motor and any driven equipment must be fully wired and assembled when the adjustable frequency drive is connected to AC line power DC power supply or load sharing 7 2 Status Messag...

Page 41: ...arning Feedback High Feedback low The sum of all active feedbacks is below the feedback limit set in 4 56 Warning Feedback Low Freeze output The remote reference is active which holds the present spee...

Page 42: ...input or serial communication Start delay In 1 71 Start Delay a delay starting time was set A start command is activated and the motor starts after the start delay time expires Start fwd rev Start for...

Page 43: ...aximum 15 mA or minimum 590 A short circuit in a connected potentiometer or incorrect wiring of the potentiometer can cause this condition Troubleshooting Remove the wiring from terminal 50 If the war...

Page 44: ...the measured motor current Display the thermal drive load on the LCP and monitor the value When running above the adjustable frequency drive continuous current rating the counter increases When runni...

Page 45: ...power to the adjustable frequency drive and repair the ground fault Check for ground faults in the motor by measuring the resistance to ground of the motor leads and the motor with a megohmmeter ALARM...

Page 46: ...Remove the power to the adjustable frequency drive and replace the brake resistor see 2 15 Brake Check WARNING ALARM 26 Brake resistor power limit The power transmitted to the brake resistor is calcul...

Page 47: ...er EEPROM data is defective or too old Replace power card No Text 512 519 Internal fault Contact the Danfoss supplier or Danfoss Service Department 783 Parameter value outside of minimum maximum limit...

Page 48: ...47 24 V supply low The 24 V DC is measured on the control card This alarm appears when the detected voltage of terminal 12 is 18 V Troubleshooting Check for a defective control card WARNING 48 1 8 V s...

Page 49: ...ount of current can be supplied to the adjustable frequency drive whenever the motor is stopped by setting 2 00 DC Hold Preheat Current at 5 and 1 80 Function at Stop ALARM 67 Option module configurat...

Page 50: ...et to 0 Frozen configuration and the option layout has been changed To apply the change enable option layout changes in 14 89 Option Detection Alternatively restore the correct option configu ration W...

Page 51: ...requency drive 3 right inverter module in F2 or F4 adjustable frequency drive 5 rectifier module WARNING 250 New spare part A component in the adjustable frequency drive has been replaced Troubleshoot...

Page 52: ...eck if the motor is connected and the connection is not interrupted by a service switch or other device Connect the motor and check the service switch No line power with 24 V DC option card If the dis...

Page 53: ...ions Perform pre start up check for loose connections Tighten loose connections Line power current imbalance greater than 3 Problem with line power see Alarm 4 Mains phase loss description Rotate inpu...

Page 54: ...0 17 0 20 0 26 7 Continuous kVA 208 V kVA 0 65 0 86 1 26 1 66 2 38 2 70 3 82 4 50 6 00 Maximum input current Continuous 200 240 V A 1 6 2 2 3 2 4 1 5 9 6 8 9 5 11 3 15 0 Intermittent 200 240 V A 2 6...

Page 55: ...200 240 V A 35 2 30 8 44 8 46 2 67 2 59 4 Additional specifications IP20 maximum cable cross section2 for line power brake motor and load sharing mm2 AWG 10 10 8 8 10 10 8 8 35 2 IP21 maximum cable cr...

Page 56: ...74 8 102 88 0 120 114 156 143 195 169 Additional specifications IP20 maximum cable cross section for line power brake motor and load sharing mm2 AWG 35 2 50 1 50 1 150 300 MCM 150 300 MCM IP21 IP55 I...

Page 57: ...2 8 3 9 5 0 6 9 9 0 11 Continuous kVA 460 V kVA 0 9 1 3 1 7 2 4 2 7 3 8 5 0 6 5 8 8 11 6 Maximum input current Continuous 380 440 V A 1 2 1 6 2 2 2 7 3 7 5 0 6 5 9 0 11 7 14 4 Intermittent 380 440 V A...

Page 58: ...s overload 380 440 V A 35 2 31 9 46 4 37 4 54 4 44 64 60 5 Continuous 441 500 V A 19 25 25 31 31 36 36 47 Intermittent 60 s overload 441 500 V A 30 4 27 5 40 34 1 49 6 39 6 57 6 51 7 Additional speci...

Page 59: ...146 200 177 Continuous 441 500 V A 47 59 59 73 73 95 95 118 118 145 Intermittent 60 s overload 441 500 V A 70 5 64 9 88 5 80 3 110 105 143 130 177 160 Additional specifications IP20 maximum cable cros...

Page 60: ...V kVA 1 7 2 5 2 8 3 9 5 0 6 1 9 0 11 0 Continuous kVA 575 V kVA 1 7 2 4 2 7 3 9 4 9 6 1 9 0 11 0 Maximum input current Continuous 525 600 V A 1 7 2 4 2 7 4 1 5 2 5 8 8 6 10 4 Intermittent 525 600 V A...

Page 61: ...t at 550 V A 28 23 33 28 41 36 52 43 59 54 Continuous at 575 V A 16 20 20 24 24 31 31 37 37 47 Intermittent at 575 V A 26 22 32 27 39 34 50 41 56 52 Additional specifications IP20 maximum cable cross...

Page 62: ...18 105 143 137 Continuous at 575 V A 47 56 56 75 75 91 91 119 Intermittent at 575 V A 70 62 85 83 113 100 137 131 Additional specifications IP20 maximum cable cross section for line power and motor mm...

Page 63: ...3 8 5 4 6 6 9 0 12 0 Maximum input current Continuous 525 550 V A 1 9 2 4 3 5 4 4 5 5 8 1 9 9 Intermittent 525 550 V A 3 0 3 9 5 6 7 0 8 8 12 9 15 8 Continuous 551 690 V A 1 4 2 0 2 9 4 0 4 9 6 7 9 0...

Page 64: ...us KVA at 690 V KVA 15 5 21 5 21 5 26 3 26 3 32 3 32 3 40 6 Maximum input current Continuous at 550 V A 15 0 19 5 19 5 24 0 24 0 29 0 29 0 36 0 Intermittent 60 s overload at 550 V A 23 2 21 5 31 2 26...

Page 65: ...ns Maximum cable cross section for line power and motor mm2 AWG 150 300 MCM Maximum cable cross section for load share and brake mm2 AWG 95 3 0 Maximum cable cross section2 for line power disconnect m...

Page 66: ...power factor cos near unity 0 98 Switching on input supply L1 L2 L3 power ups 7 5 kW maximum 2 times min Switching on input supply L1 L2 L3 power ups 11 75 kW maximum 1 time min Switching on input sup...

Page 67: ...e Design Guide for Derating for high ambient temperature Derating for high altitude 2 Determined according to EN50598 2 at Rated load 90 rated frequency Switching frequency factory setting Switching p...

Page 68: ...37 3 See chapter 4 8 5 Safe Torque Off STO for further information about terminal 37 and STO 4 When using a contactor with a DC coil inside in combination with STO it is important to make a return way...

Page 69: ...put Programmable digital pulse outputs 2 Terminal number 27 291 Voltage level at digital frequency output 0 24 V Maximum output current sink or source 40 mA Maximum load at frequency output 1 k Maximu...

Page 70: ...ll kW 1 FC 302 all kW 2 Relay 01 terminal number 1 3 break 1 2 make Maximum terminal load AC 1 1 on 1 3 NC 1 2 NO Resistive load 240 V AC 2 A Maximum terminal load AC 15 1 Inductive load cos 0 4 240 V...

Page 71: ...ponent breakdown inside the adjustable frequency drive first fault NOTICE Use of fuses on the supply side is mandatory for IEC 60364 CE and NEC 2009 UL compliant installations Recommendations gG type...

Page 72: ...32 PKZM0 25 25 B1 7 5 10 5 5 7 5 gG 25 5 5 gG 32 7 5 gG 80 PKZM4 63 63 B2 15 11 gG 50 gG 100 NZMB1 A100 100 B3 7 5 5 5 gG 25 gG 63 PKZM4 50 50 B4 10 20 7 5 15 gG 32 7 5 gG 50 11 gG 63 15 gG 125 NZMB1...

Page 73: ...15 20 11 15 gG 40 gG 80 PKZM4 63 63 B2 25 30 18 5 22 gG 50 18 5 gG 63 22 gG 100 NZMB1 A100 100 B3 15 20 11 15 gG 40 gG 63 PKZM4 50 50 B4 25 40 18 5 30 gG 50 18 5 gG 63 22 gG 80 30 gG 125 NZMB1 A100 1...

Page 74: ...B2 A200 160 C2 100 75 aR 200 75 aR 250 NZMB2 A250 250 C3 50 60 37 45 gG 63 37 gG 100 45 gG 150 NZMB2 A200 150 C4 75 100 55 75 aR 160 55 aR 200 75 aR 250 NZMB2 A250 250 Table 8 15 525 600 V Enclosure T...

Page 75: ...K 05 R FWX 5 HSJ 6 0 75 1 5 0 55 1 1 5017906 010 KLN R 10 ATM R 10 A2K 10 R FWX 10 HSJ 10 2 1 5 5017906 016 KLN R 15 ATM R 15 A2K 15 R FWX 15 HSJ 15 3 2 2 5017906 020 KLN R 20 ATM R 20 A2K 20 R FWX 20...

Page 76: ...ann JFHR2 Ferraz Shawmut J Ferraz Shawmut JFHR21 Littelfuse JFHR2 0 5 1 5 0 37 1 1 5017906 006 KLS R 6 ATM R 6 A6K 6 R FWH 6 HSJ 6 2 3 1 5 2 2 5017906 010 KLS R 10 ATM R 10 A6K 10 R FWH 10 HSJ 10 4 3...

Page 77: ...80 JJS 80 5014006 080 KLS R 075 A6K 80 R HSJ 80 50 37 KTS R 100 JKS 100 JJS 100 5014006 100 KLS R 100 A6K 100 R HSJ 100 60 45 KTS R 125 JKS 125 JJS 125 2028220 125 KLS R 125 A6K 125 R HSJ 125 75 55 K...

Page 78: ...8 8 Connection Tightening Torques Torque in lb Nm Enclosure Line power Motor DC connection Brake Ground Relay A2 15 93 1 8 15 93 1 8 15 93 1 8 15 93 1 8 26 55 3 5 31 0 6 A3 15 93 1 8 15 93 1 8 15 93...

Page 79: ...55 268 14 76 375 10 55 268 14 76 375 15 35 390 16 54 420 18 9 480 25 59 650 15 71 399 20 47 520 26 77 680 30 32 770 21 65 550 25 98 660 35 79 909 Height with de coupling plate for serial communi catio...

Page 80: ...4 260 10 24 260 10 32 262 9 53 242 12 21 310 13 19 335 13 11 333 13 11 333 14 76 375 Screw holes in mm c 0 24 6 0 0 315 8 0 0 315 8 0 0 315 8 0 0 315 8 0 0 33 8 25 0 33 8 25 0 47 12 0 47 12 0 315 8 0...

Page 81: ...r PELV Protective extra low voltage PCB Printed circuit board PWM Pulse width modulated ILIM Current limit IINV Rated inverter output current RPM Revolutions per minute Regen Regenerative terminals ns...

Page 82: ...imum Reference 2 06 Parking Current 2 07 Parking Time 2 1 Brake Energy Funct 2 10 Brake Function 2 11 Brake Resistor ohm 2 12 Brake Power Limit kW 2 13 Brake Power Monitoring 2 15 Brake Check 2 16 AC...

Page 83: ...back 1 Resource 7 22 Process CL Feedback 2 Resource 7 3 Process PID Ctrl 7 30 Process PID Normal Inverse Control 7 31 Process PID Anti Windup 7 32 Process PID Start Speed 7 33 Process PID Proportional...

Page 84: ...og Settings 15 10 Logging Source 15 11 Logging Interval 15 12 Trigger Event 15 13 Logging Mode 15 14 Samples Before Trigger 15 2 Historic Log 15 20 Historic Log Event 15 21 Historic Log Value 15 22 Hi...

Page 85: ...ave Marker Type 33 21 Master Marker Tolerance Window 33 22 Slave Marker Tolerance Window 33 23 Start Behavior for Marker Sync 33 24 Marker Number for Fault 33 25 Marker Number for Ready 33 26 Velocity...

Page 86: ...1 Software Readouts 99 13 Idle time 99 14 Paramdb requests in queue 99 15 Secondary Timer at Inverter Fault 99 16 No of Current Sensors 99 17 tCon1 time 99 18 tCon2 time 99 19 Time Optimize Measure 99...

Page 87: ...ption 45 Conduct 22 Control card Control card 41 68 Control card 68 69 Control characteristic 69 Control signal 38 Control terminal 25 27 38 40 Control wiring 13 15 19 22 Control word timeout 43 Conve...

Page 88: ...Local control panel LCP 23 M Main menu 24 Maintenance 38 Manual initialization 26 MCT 10 18 23 Mechanical brake control 20 37 Mechanical installation 10 Menu key 24 Menu structure 24 Modbus RTU 21 Mo...

Page 89: ...8 25 38 39 40 68 Service 38 Setpoint 40 Set up 24 31 Shielded cable 15 22 Shock 10 Short circuit 43 SLC 37 Sleep mode 40 SmartStart 26 Specifications 21 Speed reference 20 31 33 38 Speed reference ana...

Page 90: ...bration 10 Voltage imbalance 41 Voltage level 66 W Warnings 40 Weight 77 Windmilling 9 Wire size 13 16 Wiring schematic 15 Index Instruction Manual 88 Danfoss A S Rev 09 2014 All rights reserved MG33A...

Page 92: ...at alterations to products already on order shall not require material changes in specifications previously agreed upon by Danfoss and the Purchaser All trademarks in this material are property of the...

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